Heating Instruction

SECTION 4.
INSTRUCTIONS FOR
FREEZE DRYING PLANT
CONRAD™ 600 XL eco
HEATING SYSTEM
Please read the instructions provided in this section of Instruction Handbook thoroughly.
All plant personnel must be familiar with these instructions. Failure to follow these
instructions may result in injury, fatal accident and plant damage.
0610-0xxx
4009 en
032-7024
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GEA Process Engineering
Copyright © 2015 GEA Process Engineering A/S. All rights reserved.
0610-0xxx CONRAD™ 600 XL eco
4009 en Heating System
TABLE OF CONTENTS PAGE

1. DESCRIPTION OF THE HEATING SYSTEM .................................................................1
1.1 General.............................................................................................................................1
2. SAFETY ISSUES .............................................................................................................2
2.1 Persons responsible for the safety ..............................................................................2
2.2 General safety issues .....................................................................................................2
3. ENVIRONMENTAL PROTECTION .................................................................................3
3.1 Disposal ...........................................................................................................................4
4. TECHNICAL DATA ..........................................................................................................5
4.1 Main data .........................................................................................................................5
4.1.1 Cold water tank unit, sketch .............................................................................................7
4.1.2 Hot water tank unit, sketch ...............................................................................................8
4.1.3 Hot water tank, sketch ......................................................................................................8
4.1.4 Cold water tank, sketch ....................................................................................................9
4.1.5 Regulating units, sketch ...................................................................................................9
5. INSTALLATION .............................................................................................................10
5.1 Storage...........................................................................................................................10
5.1.1 Placing ............................................................................................................................10
5.2 Erection of pipe system ...............................................................................................10
5.3 Handling of components .............................................................................................11
5.4 Pressure test of the heating system...........................................................................11
5.5 Insulation of pipes and tanks ......................................................................................12
5.6 Charging water into the system ..................................................................................12
5.6.1 Water quality ...................................................................................................................13
6. OPERATION...................................................................................................................14
6.1 Operational modes .......................................................................................................14
6.2 Hot water tank - Temperature control ........................................................................15
6.3 Cold water tank - Temperature control ......................................................................16
6.4 Emergency cooling.......................................................................................................17
6.5 Expansion vessel..........................................................................................................18
6.6 Arrangement for heating regulation units .................................................................20
6.6.1 Temperature control - Zone 1 .........................................................................................22
6.6.8 Temperature control - Zone 10 .......................................................................................31
6.7 Set points.......................................................................................................................34
7. MAINTENANCE .............................................................................................................35
GEA Niro
CONRAD™ 600 XL eco 0610-0xxx
Heating System 4009 en
7.1 Emptying of system ..................................................................................................... 35

7.2 Regular check points ................................................................................................... 35
8. SPARE PARTS .............................................................................................................. 36
8.1 Ordering of spare parts................................................................................................ 36
8.2 Spare parts .................................................................................................................... 36
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1. DESCRIPTION OF THE HEATING SYSTEM
1.1 General
See drawing no. 1149459: P/I – Diagram Heating Systems
The main purpose of the Heating System is to act as heat carrier to the sublimation
process in the CONRAD™ cabinet.
The Heating System is equipped with two tanks. One tank, with a volume of 4300
Litres, is used for accumulating hot water, and the other tank, with a volume of 10.000
Litres, is used for accumulating cold water.
The hot water is heated with steam in a heat exchanger and re-circulated by a pump.
The pump will always be running during automatic operation.
The system is equipped with a cold-water system for emergency situations. The cold
water is cooled with cooling-water in a heat exchanger, circulated by a pump. The
water temperature in the tank controls the pump. With this system it is possible to cool
the heating plates in case of loss of vacuum, thus preventing the coffee charge in the
cabinet from boiling.
Both the hot-water and cold-water tanks are connected to a common expansion tank
with a volume of 1500 Litres. Air pressure between 5.4-5.5 Barg is maintained in the
expansion tank to prevent the water from boiling when heated to temperatures above
100°C.
The heated water is distributed into 12 independently controlled temperature zones for
the Conrad™ Cabinet. Each temperature zone has a circulation pump for circulation of
water through the heating plates. By means of the temperature transmitters and the
temperature control valves in each of the 12 zones the operator is able to set the
wanted heating profile.
For temperature zone no. 12, the outlet end is connected to a heat exchanger for
cooling down freeze dried coffee granules to the desired temperature before discharge
from the cabinet.
A small pipe connects the pressure side of the pump in zone 12 to the suction side of
the pump in zone 11 through a two-way automatic on/off valve.
If the required temperature in zone 11 cannot be obtained by recirculation, the valve
will be opened and bring in additional cooling water from zone 12.
Further zones 1 - 5 are equipped with a flow meter, which will give an alarm if no flow
is measured.
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1/33 GEA Process Engineering
2. SAFETY ISSUES
2.1 Persons responsible for the safety
User:
A user is any natural or legal person that uses the heating system or at whose request
the heating system is used.
The user or his safety representative must ensure that:

 All relevant rules and regulations are observed
 Only qualified personnel are working at and with the heating system
 The operation manuals are available to the personnel for all relevant tasks
 Unqualified personnel are not allowed to work at and with the heating system
Qualified personnel:
Qualified personnel are persons who, based on their education, experience, special
training and knowledge of relevant standards and stipulations, safety regulations and
operating conditions, are authorized by the person responsible for the safety in the
plant to perform the necessary actions and who are able to recognize and avoid
possible danger.
2.2 General safety issues
Warning!
It is of the utmost importance that any operator of the heating system
has read and understands the guidelines in the manuals including
those from the sub-suppliers.
All electrical installation and/or repair work is to be carried out by

professional electricians.
The Heating System has an operating temperature of up to max. 140C and precaution
must be taken at all times to prevent personal injury.
Warning!
If it is necessary to open parts of the system for maintenance certain
precautions must be taken in order to avoid personal injury.
 The relevant circulation pumps must be stopped and the service switch must be
switched off and secured with a padlock.
 The temperature in the part of the system concerned must be checked on the
monitor in the control room or locally. The system may not be opened until the
temperature is below 55°C.
 The part of the system concerned must be isolated by closing the relevant stop
valves. The valves must be secured against accidental opening.
 The pressure must be released slowly from the isolated system.
 Maintenance on the Heating System may only be performed by qualified
personnel.
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GEA Process Engineering 2/33
Before personnel enter the CONRAD™ cabinet for maintenance it must be secured
that the heating plates are cooled down to a reasonably low temperature. It is
recommended to cool the heating plates to 40°C before entering the CONRAD™
cabinet.
The heating system is supplied with three safety valves:

 F2500 on the air side of the expansion tank
 F2800 on the water side of the heating system.(Placed on cold water holding tank)
 F2204 in heating circuit for hot water tank. (safety for the heat exchanger system)
The safety valves are set to open at following pressures:

 F2500 at 5.65 bar g
 F2800 at 5.8 bar g (Factory adjusted)
 F2204 at 10.0 bar g
During installation of the valves it must be secured, that discharge from the valves can
flow freely and that discharged water/steam cannot cause injury to personnel.
All pipes warmer than 55°C must be insulated where possible. In case of pumps and
valves that cannot be insulated, a warning sign like the one below (hot surface) must
be attached.
3. ENVIRONMENTAL PROTECTION
Many countries have legislated in the area in an attempt to reduce pollution and protect
the environment. Such environmental protection acts that are to be observed concern
all sectors of the industry.
It is the obligation of the end-user to ensure that local environmental rules are adhered
to, with regard to disposal of consumables and other waste products from the process.
Especially, please be aware of the following liquids:
 Lubricants
 Waste water
Lubricants:
Wherever possible, food approved lubricants (FDA; USDA H1) are used.
At change of oil, the waste oil must be collected in a vessel and sent to an authorized
destructor.
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Waste Water:
The Heating System is a closed circulation system and thus normally no water is led to
the drain. If, however, the system is opened and drained the water must be led to a foul
water drain.
3.1 Disposal
What? Where?
Transport Pallets To be returned to manufacturer or

materials forwarding agent.
Packaging Cardboard to paper recycling.
Plastic to plastic recycling or
residual waste.
Lubricants Oil, grease To be disposed of according to local
regulations.
Components Motors Electrical Should be returned to the motor
supplier or other specialist for
disposal.
Actuators Steel Should be returned to the supplier or
Seals other specialist for disposal.
Electrical
Valves Cast iron Housing and seals to be dismantled
Sealing and disposed of separately.
Piping and Mild Steel To be sent to scrap yard for
fittings recycling.
Instruments Stainless steel Should be returned to supplier or
Plastic other specialist for disposal.
Special waste
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4. TECHNICAL DATA
4.1 Main data
Heating system CONRAD™ 600 XL

Weight:
Hot water tank kg 1965
Cold water tank: kg 2950
Expansion tank: kg 800
Hot water tank unit: kg 714
Cold water tank unit: kg 859
Regulation units: kg 156-308
Dimensions: Length Width Height
Hot water tank: mm 4000 1430 1610

Hot water tank unit: mm 2873 1480 1762
Cold water tank: mm 2190 2345 3719
Cold water tank unit: mm 2906 1275 2206
Expansion tank: mm 1200 1200 2050
Regulation units: mm 365-1546 866,5-1561 2550-3800
Pump Specifications:
Nom.Diam Pressure Flow
3
Function Type inlet/outlet mlc m /h
Hot water tank ETLY 065-065-200/200 DN65 12,5 40
G2202
Cold water tank ETLY 065-065-200/200 DN65 12,5 40
G2802
Zone 1, 2, 3, 4 ETLY 065-065-200/203 DN65 12,5 46
G2010,
G2020,
G2030,
G2040
Zone 5, 6 ETLY 065-065-200/200 DN65 12,5 40
G2050,
G2060,
Zone 7,8,9,10 ETLY 065-065-200/191 DN65 12.85 20
G2070,
G2080,
G2090,
G2100
Zone 11, 12 ETLY 050-050-200/192 DN50 11.75 14
G2110,
G2120,
Electrical supply
50Hz:
Pmotor kW 2.2
Circulation pump DN65 Umotor V 3 x 400
Hot water tank In A 4.8
(G2202) Speed rpm 1450
Start DOL
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Circulation pump DN 65 Pmotor kW 2,2
Cold water tank Umotor V 3 x 400
(G2802) In A 4.8
Speed rpm 1450
Start DOL
(G2010, G2020, G2030, G2040) Umotor V 3 x 400
In A 6,2
Speed rpm 1450
Start DOL
(G2050, G2060) Umotor V 3 x 400
In A 4,8
Speed rpm 1450
Start DOL
(G2070, G2080, G2090, G2100) Umotor V 3 x 400
In A 3,5
Speed rpm 1450
Start DOL
(G2110, G2120) Umotor V 3 x 400
In A 1,9
Speed rpm 1450
Start DOL
Connections:
Steam
Inlet; pipe: mm DN65
Quantity: kg/h 1500
Pressure: Bar g 6
Temperature °C 165
Circulated chilled water

Inlet; pipe: mm DN50
3
Quantity: m /h 2,5
Pressure: Bar g 2
Temperature °C 2
Circulated chilled water heating zone 10

Connection: mm DN50
3
Quantity: m /h 5
Pressure: Bar g 2
Temperature °C 2
For distribution of compressed air to the pneumatic actuators, please see the
pneumatic diagram drawing 1149463.
All pumps are of the manufacture KSB.
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Vessel contents
Hot-water tank: 4300 litres
Cold-water tank: 10000 litres
Expansion tank: 1500 litres
4.1.1 Cold water tank unit, sketch
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4.1.2 Hot water tank unit, sketch
4.1.3 Hot water tank, sketch
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4.1.4 Cold water tank, sketch
4.1.5 Regulating units, sketch
Regulating unit
DN 65, DN 50
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5. INSTALLATION
5.1 Storage
If the Heating System is not installed immediately, suitable storage conditions must be
provided.
Up to a year: Dry, frost-free and dust-free rooms protected from sunlight.

Over a year: Please contact the manufacturer.
5.1.1 Placing
Sufficient space around the components for inspection, operation, cleaning and
maintenance is recommended.
Please see recommended arrangement on the installation drawings:
CONRAD line : 1172575, 1172406, 1172992, 1172644 & 1173447
5.2 Erection of pipe system
All pipes and fittings must be clean inside. After cutting, the cutting edge must be
removed and cuttings inside the pipes must be removed.
Cutting should always be made at 90° to the pipe axis to ensure parallel pipes and
proper welds. To facilitate welding the pipe must be sharpened after cutting.
If flame cutting is used, the scales must be removed by careful grinding until clean
metal is available for making a proper weld. Preferably a mechanical cold saw should
be used for cutting the pipes.
When welding flanges it must be ensured that the flange has a 90° angle to the pipe
axis. Otherwise it will be difficult to tighten the flanges and a lot of tension will be
created in the pipes.
The pipes should be measured out carefully according to the arrangement drawing and
the actual conditions on site. Do not force pipes into position, otherwise tension will be
created or the pipes will be broken.
As the Hot Water System carries water up to 140°C with a pressure of 5.5 bar g, only
skilled welders should be allowed to weld on the pipes and fittings. The welders must
hold valid certificates allowing them to weld on pressurized systems.
The best quality of welding is obtained with TIG/Argon welding as it will leave no scales
inside the pipes. If electrode welding is used great care must be taken to clean the
pipes, for example by blowing pressurized air through the pipes after welding.
When bolting together flanges remember to grease the bolts with a suitable type of
grease, i.e. copper grease or Molycote. Never grease non-asbestos gaskets.
When using threaded connections, a good quality of packing yarn and packing grease
should be used.
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A sufficient number of pipe supports must be used to ensure that load is not applied to
pumps and valves.
5.3 Handling of components
Before installation of components such as pumps and valves please ensure that
protection covers like plastic plugs are removed and that the components are clean
inside.
It must be checked that direction arrows on pumps and valves are according to the flow
diagram. Also check that A/B/AB indications on 3-way valves are according to the flow
diagram.
Valves and pumps must be protected against welding drops during erection.
Components should be handled with care as valve positioners and shaft seals of
pumps could be damaged by mechanical shock.
5.4 Pressure test of the heating system
Before pressure testing it must be checked that all internal stop valves in the system
are open.
Air is pressed into the system until a pressure of MAX. 1.2 bar g is obtained.
All welds and connections in the plant shall then be carefully leakage tested by means
of soapy water, and leaks are to be marked for repair. After blow off to the open air, the
possible leaks are to be repaired.
After the repair, air is pressed into the plant again to a pressure of MAX. 1.2 bar g. All
welds and connections are tested again using soapy water. When no leaks are found
the pressure is blown off.
Clean water is pressed into the system until a pressure of approx. 6.6 bar g is obtained
corresponding to 1.2 times the working pressure.
Close the inlet valve and wait for 24 hours. If no pressure drop is observed the system
is tight and ready to be filled with treated water.
Please note that special precautions for the expansion unit must be taken before filling
water into the system according to separate instructions from the supplier of the
expansion vessel.
Never insulate welds or connections before the leakage test has been carried out and
approved.
A pressure test report with the following contents must be made:
Date of pressure test

Who made the test
Remarks
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5.5 Insulation of pipes and tanks
As the Heating System contains water with temperatures of more than 140°C the hot
water pipes and hot water tank must be insulated.
Mineral wool is used as insulation. The layer thickness should be minimum 50 mm.
Before insulation, the pipes and welds are to be painted with a suitable primer to
prevent corrosion.
5.6 Charging water into the system
When charging the system with water it is necessary to purge all air from the system.
Valves for air purging are placed on the header-pipes.
Air must also be purged from the expansion tank before filling with water.
(See separate instructions for the expansion tank)
When it has been verified that the circulation pumps are filled with water they can be
started in order to circulate water to the heating plate sections. During filling the control
valves can be set manually to 50% to allow water to fill-up the entire system.
Air trapped in the pipes will block the circulation of water. Without circulation the
temperature regulation will not work and the desired temperatures cannot be
maintained.
Stop!
Never start the circulation pumps in dry condition. Running without
water filling will damage the shaft seal.
When the total system is filled with water and all air has been purged a water level of
approximately 20% must be present in the expansion tank.
One leg of the expansion tank is positioned on a load cell. The 4 to 20 mA signal from
the weighing transmitter can be transformed to indicate 0% to 100% level in the tank.
The level is indicated on the picture for control of the temperature in the hot/cold-water
tanks. If the water level drops below 5% a LOW-LEVEL ALARM will appear in the
alarm list. The cause of the alarm must be found immediately.
Causes of LOW-LEVEL ALARM could for instance be:
- Leak in heat exchanger for water heating.

- Leak in heat exchanger for water cooling.
- Leak in heating plates or connection hoses inside CONRAD™ cabinet.
Pressurizing of the expansion tank may not take place before all the air has been
purged from the water system. Heating of the system may not take place before the
system has been pressurized.
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5.6.1 Water quality
The quality of the water to be charged must protect the pipes and heating plates
against corrosion.
Analysis of a suitable water quality:
Conductivity: below 20 μS/cm

PH: between 7-8
CO2: below 25 mg/l
O2: below 0.02 mg/l
Cl-: below 0.5 mg/l
Ca: below 0.02 mg/l
Mg: below 0.02 mg/l
Fe: below 0.05 mg/l
Cu: below 0.01 mg/l
F-: below 1.0 mg/l
Permanganate: below 10 mg/l
SiO2: below 0.02 mg/l
Hardness: below 0.02 dH (mval/kg)
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6. OPERATION
6.1 Operational modes
HEATING START
HEATING START must be activated before starting the Tray Transport System.
NOTE: If the Tray Transport System is running and cold trays are circulated through
the CONRAD™ cabinet without the Heating System is started, a serious risk
exists that water in the heating plates will freeze due to radiation from the cold
trays thus causing damage and maybe even bursting of the heating plates.
Therefore the control system is designed so that the circulating pumps for the
heating zones 1 to 4 must be running before the Tray Transport System can
be started.
The relays for pumps G2010, G2020, G2030 and G2040 are hardwired in a
safety loop securing that the Tray Transport System cannot run if just one of
the circulating pumps is stopped,
If the temperature of the circulating water in any of the heating zones 1 to 4 is

below 15ºC, the Tray Transport System has to STOP.
If the pumps of the circulating water in any of the heating zones 1 to 4 not are
running, the Tray Transport System has to STOP.
HEATING STOP
HEATING STOP must be activated if the system is not going to be operated for a long
period.
If the Tray Transport System is stopped in production mode for more than 30 minutes,
the heating profile must be modified and the temperatures for the zones must be
changed approximately every 30 minutes.
EMERGENCY COOLING
EMERGENCY COOLING can be activated when vacuum failure appears.

The Tray Transport System should be stopped at the same time.
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6.2 Hot water tank - Temperature control
The circulation pump - G2202 - takes water from the lower connection on the hot water
holding tank C2200 and circulates it through the secondary side of the plate heat
exchanger E2300. The water is returned to the upper connection on the hot water
holding tank. On the primary side the heat exchanger is heated by steam at a pressure
of maximum 6 bar g. By means of a pressure reducing valve the steam pressure can
be adjusted to the most suitable pressure. It is recommended to adjust the steam
pressure to be as low as possible as it will extend the lifetime of the plate heat
exchanger.
During automatic operation the pump G2202 will always be running.
Stop!
The pump must run before steam is supplied to the heat exchanger
E2300. If the pump stops, the steam supply must also be stopped
by closing the valve Q2200.
Stop!
If one of the following alarms from expansion tank is active:
Low Low Pressure from K2500
Low Low Level from P2500
then pump G2200 must stop and valve Q2200 must
close to stop the energy supply to the system.
Stop!
The drain valve Q2212 must be secured against accidental opening
by removing the handle and closing the outlet with a plug.
The two-way valve Q2200 controls the temperature in the hot water holding tank as
measured by the temperature element K2200 by regulating the steam supply to plate
heat exchanger E2300.
The valve is controlled by a pneumatically operated actuator with positioner operating

from 0% to 100%.
The position of the valve is indicated on the screen and the set point can be selected
from the display.
The temperature element type PT100 tag no. K2200 registers the water temperature in
the hot water holding tank C2200 and a PID regulator controls the opening of steam
valve Q2200 for heat exchanger E2300 to maintain the set point temperature.
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The set point for the water temperature in the hot water holding tank C2200 as well as
the corresponding alarm set points can be selected from the display.
HIGH TEMPERATURE ALARM: 145C

SET POINT: 140C
LOW TEMPERATURE ALARM: 135C
6.3 Cold water tank - Temperature control
The circulation pump - G2802 - takes water from the upper connection on the cold
water holding tank C2800 and circulates it through the primary side of the plate heat
exchanger E2900. The water is returned to the lower connection on the cold water
holding tank.
On the secondary side of the heat exchanger cooling water is circulated.
When EMERGENCY COOLING of the heating plates is performed the temperature in

the cold water holding tank will increase to approximately 50C. The temperature is
registered by temperature sensor K2800.
During automatic operation the pump is controlled by the temperature sensor K2800 in
the cold water holding tank.
If the temperature becomes 5°C higher than the set point the pump will start. When the
temperature has fallen to the set point the pump will stop again.
The set points can be selected from the display.
Start of pump: 35 °C
Stop of pump: 30 °C
Stop!
The tank is connected to the expansion vessel and is therefore
under pressure (5.4-5.5 bar). The tank is fitted with a safety valve
which is factory-adjusted to 5.8 bar. The outlet from the valve must
be led to a drain where warm water can safely be ejected in case of
release from the safety valve.
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Stop!
The drain valve Q2810 must be secured against accidental opening
by removing the handle and closing the outlet with a plug.
6.4 Emergency cooling
The three-way valve Q2210 controls the flow of either hot water or cold water to the
heating-plate sections in the CONRAD™. The valve can take two positions:
L (B→AB) and H (A→AB).
In position L (B→AB) cold water will flow from the cold-water holding tank to the
heating plates. In position H (A→AB) hot water will flow from the hot-water holding tank
to the heating plates.
The three-way valve Q2211 controls the flow of the return water from the heating plate
sections in the CONRAD™. The valve has been placed to avoid backflow between the
hot water tank and the cold water tank.
In normal operation, where heated water is being used, the valves will take position H
(AB→A), returning the water to the hot water tank C2200.
During emergency cooling where cooled water is being used, the valves will take
position L (AB→B), returning the water to the cold water tank C2800.
In AUTOMATIC mode the valves will take position H for both HEATING START and
HEATING STOP.
In EMERGENCY COOLING mode the valves will take position L.
Without air pressure the valves will take position L.
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6.5 Expansion vessel
To prevent the water from boiling when heated to above 100°C the expansion tank is
pressurized with air from the factory compressed air supply. The pressure transmitter
K2500 measures the actual pressure.
The valve for air supply - Q2500 - will open at a pressure of 5.2 bar g and close again
when the pressure reaches 5.4 bar g. If the pressure does not reach 5.4 bar g within 60
seconds a LOW PRESSURE ALARM will be indicated.
NOTE!
If the temperature in the hot water holding tank is below 95 ºC, air should not be
injected into the expansion tank.
At a rising temperature the water will expand and the level and pressure in the
expansion tank will increase. To avoid lifting of the safety valves the increasing air
pressure is released through a solenoid valve - Q2501. The air discharge valve will
open when the pressure reaches 5.6 bar g and close when the pressure drops below
5.4 bar g. If the pressure fails to reach 5.4 bar g in 60 seconds a HIGH PRESSURE
alarm will be indicated.
The expansion tank is supported on a load cell forming the level transmitter K2500.
In cold condition the level should be about 20% of maximum. In hot condition the level
will increase to about 50% of maximum. In case of low level below 5 % a LOW LEVEL
alarm will be indicated.
The set points can be changed from the display.
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Stop!
The expansion vessel is fitted with a safety valve which is
calibrated to 5.7 Bar g. The outlet from the valve must be led away
from personnel and service areas or be properly protected.
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6.6 Arrangement for heating regulation units
The heating regulation units are operated as individual units, with one regulating unit
for each of the 12 heating zones of the CONRAD™ cabinet.
Each unit in zones 1 to 11 comprises:
2 stop valves for water inlet and outlet from the hot/cold water tanks
1 three-way valve for temperature regulation
1 circulation pump
1 manometer with shut-off valve
1 strainer
1 PT-100 temperature sensor
1 flow meter (only zone 1 – 5)
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The unit for zone 12 comprises:
2 stop valves for water inlet and outlet from the hot/cold water tanks
1 three-way valve for temperature regulation
1 circulation pump
1 manometer with shut-off valve
1 strainer
1 PT-100 temperature sensor
1 three-way valve for cooling
1 heat exchanger with stop valves for cooling of zone 12 by chilled cooling water
Stop!
Valve Q21x4 is to be used for draining water from the individual
regulation units.
At normal operation, the handle must be removed and the valve
outlet closed with a plug to avoid accidental opening and leaks.
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6.6.1 Temperature control - Zone 1
The temperature transmitter P2013 is a PT 100 sensor for indication of the temperature
in the surface of the coffee granulate layer in one tray. The temperature is indicated on
the control picture for the heating plates.
The temperature sensor is automatically lifted when the tray is moving.
The 16 heating plates in zone 1 are connected to circulation pump G2010.
Stop!
The temperature in the heating plate zones 1 to 12 may not
exceed 140 ºC
Stop!
Circulation pump G2010 must run when the Tray Transport System
is in operation. Otherwise the water may freeze and damage the
heating plates.
In AUTOMATIC mode the circulation pump G2010 will START when the mode
HEATING START is activated. The pump will STOP when HEATING STOP is
activated.
The three-way valve Q2010 mixes water from the hot water holding tank with water
returned from the heating plates in order to maintain the correct temperature. Valve
connection A is connected to the hot water holding tank. Valve connection B is
connected to the return pipe from the heating plates, and valve connection AB is
connected to the circulation pump suction line.

from 0% to 100%.
At 0% the valve takes position B-AB equal to full recirculation of the water.
At 100% the valve takes position A-AB equal to full heating.
The actuator/positioner allows the valve to take any position from 0% to 100%
according to a 4-20 mA signal from a PID regulator controlled by the PLC.
The temperature transmitter type PT100 - K2010 - is connected to the PLC and
measures the actual water temperature to the heating plates. A PID-regulator in the
PLC controls the position of the valve in order to maintain a temperature equal to the
set point.
The set point can be adjusted from the display.
When EMERGENCY COOLING mode is activated the valve must take 100% position.
The valve is then fully open and maximum cooling from the cold water holding tank is
achieved.
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Stop!
is in operation. Otherwise, the water may freeze and damage the
heating plates.
In AUTOMATIC mode the circulation pump G2020 will START 5 minutes after the
mode HEATING START is activated. The pump will STOP when the mode HEATING
STOP is activated.
returned from the heating plates in order to maintain the correct temperature.
Valve connection A is connected to the hot water holding tank. Valve connection B is

from 0% to 100%.
set point.
achieved.
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Stop!
heating plates.
HEATING START is activated. The pump will STOP when the mode HEATING STOP
is activated.

from 0% to 100%.
set point.
achieved.
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Stop!
heating plates.
HEATING START is activated. The pump will STOP when the mode HEATING STOP
is activated.

from 0% to 100%.
set point.
achieved.
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In AUTOMATIC mode the circulation pump G2050 will START 3.600 seconds after the
STOP is activated.

from 0% to 100%.
set point.
achieved.
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STOP is activated.

from 0% to 100%.
The temperature transmitter type PT100 – K2060 - is connected to the PLC and
set point.
achieved.
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STOP is activated.

from 0% to 100%.
set point.
achieved.
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STOP is activated.

from 0% to 100%.
set point.
achieved.
GEA Niro
STOP is activated.

from 0% to 100%.
set point.
achieved.
GEA Niro
STOP is activated.

from 0% to 100%.
set point.
achieved.
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STOP is activated.

from 0% to 100%.
set point.
The valve is then positioned for full recirculation of water through the heating plates.
If during HEATING START mode the temperature as measured by temperature

element K2110 is higher than the set point when the three-way valve Q2110 is at full
recirculation (0%), an automatic bypass valve, Q2125, will be opened and allow cold
water from zone 12 to enter zone 11.
When EMERGENCY COOLING mode is activated the bypass valve Q2125 must take
100% position. In this way the water in zone 11 is also cooled by the heat exchanger
E2600 for zone 12.
GEA Niro
STOP is activated.
The three-way valve Q2120 mixes water from the hot water holding tank with return
water from the heating plates in order to maintain the correct temperature.
If the temperature of the circulated water is higher than the set point, the water can be
cooled by three-way valve Q2120 diverting part of the return water from the heating
plates through heat exchanger E2600 and remixing it with the rest of the flow.
The secondary side of the heat exchanger is connected to a cooling water system. In
this way it is possible to cool down the dried coffee to a temperature below room
temperature if this becomes useful.
For valve Q2120 connection A is connected to the hot water holding tank. Valve
connection B is connected to the return line from the heating plates. Valve connection
AB is connected to the circulation pump suction line.
For valve Q2126 connection A is connected to the return line from the heating plates.
Valve connection B is connected to line from heat exchanger E2600 and valve
connection AB is connected to valve connection B on valve Q2120.
The valves are controlled by pneumatically operated actuators with positioner

operating from 0% to 100%.
The actuators/positioners allow the valves to take any position from 0% to 100%
NOTE!
The valves Q2120 and Q2126 operate in “Split Range” mode.
This means that only one valve will be regulating at a time, while the other valve will
maintain its position. Further, the valve will change from 0% to 100% for only 50%
change in regulator output.
At 0% - 50% regulator output valve Q2120 takes position B-AB equal to full
recirculation of the water. At 100% regulator output the valve takes position A-AB equal
to full heating.
At 0% regulator output valve Q2126 takes position B-AB equal to full cooling.
At 50% - 100% regulator output the valve takes position A-AB equal to full recirculation.
GEA Niro
PLC controls the position of the valves Q2120 and Q2126 as indicated below to
maintain the water temperature equal to the set point.
-------------------------------------------------------------------------------------------
PID regulator output 0% 50% 100%
-------------------------------------------------------------------------------------------
Valve position Q2120 0% 0% 100%
Valve position Q2126 0% 100% 100%
-------------------------------------------------------------------------------------------
Function cooling recirculation heating
-------------------------------------------------------------------------------------------
When EMERGENCY COOLING is activated the valves must take position 0% equal to
full cooling through heat exchanger E2600.
6.7 Set points
A possible heating profile could be as indicated below, where consideration is taken to

avoid discolouration of product in heating zone no.1 and adjustment of the residual
moisture is made by keeping a very low temperature in heating zone no. 12.
The temperatures must, however, be adjusted according to the actual capacity and the
product being dried.
Heating zone 1 (K2010): 60 C

GEA Niro
7. MAINTENANCE
As the Heating System is composed of standard components from various suppliers,

the details concerning specific maintenance work can be found in the manufacturers’
manuals in section 4.
However, no part of the heating system needs any special maintenance. Only a visual
inspection should be made daily to find leaks or abnormal sounds from any of the
components.
7.1 Emptying of system
Before the entire system or parts of the system are emptied it must be secured that the
temperature in the part of the system concerned is below 55°C. The temperature can
be checked on the monitor in the control room.
The pressure in the part of the system concerned must be released and the relevant
stop valves must be closed in order to isolate the system. The stop valves must be
secured against accidental opening.
NOTE!
Only qualified personnel may perform charging and emptying of water.
7.2 Regular check points
HEATING SYSTEM
CONTROL POINT d w m q y ACTION REMARKS
Heating system x Check the water Always in connection
quality with filling or refilling
x Air-purge the system
Water circulating x Inspect for leakage If defective, replace
pumps the packing set.
Strainers x Cleaning First cleaning after
1 week.
Second cleaning after
1 month.
Third cleaning after
6 months.
Expansion vessel x Check the water Refill with treated wa-
level ter if required.
Find cause of leakage
Shut-off valves x Lubricate spindle
x Check operation of
valve from 0-100%
Safety valve x Check function of Local regulations may
valve specify other intervals.
Regulating valves x Check adjustment of
the positioner
x Check movement of
valve from 0 to 100%
d = daily, w = weekly, m = monthly, q = quarterly, y = yearly
GEA Niro
8. SPARE PARTS
8.1 Ordering of spare parts
When contacting the service department of GEA Niro, please inform of full part number
(6 digits) from the spare parts list. This part number unambiguously identifies the
requested spare part.
Refer to the original GEA Niro main order no. (032-7024) and the supplied machinery.
For contact about service or other information, state machine type, serial number and
year of manufacture. These data appear from the nameplates.
Drives
Type designation appears from the nameplate on the drive.
For ordering of separate parts for a drive renovation, please see the supplier’s
instructions for repair, which are enclosed with this manual.
Pneumatic valves
Pneumatic components can be ordered from GEA Niro or according to the supplier’s
diagram and parts list, which are enclosed with this manual.
8.2 Spare parts
The necessary spares in order to ensure reliable operation have to be provided before
commissioning and start-up in accordance with the separate spares catalogue located
in this manual.
GEA Niro

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SECTION 4.

FREEZE DRYING PLANT

CONRAD™ 600 XL eco

TABLE OF CONTENTS PAGE

7.1 Emptying of system ..................................................................................................... 35

1. DESCRIPTION OF THE HEATING SYSTEM

See drawing no. 1149459: P/I – Diagram Heating Systems

2.1 Persons responsible for the safety

The user or his safety representative must ensure that:

2.2 General safety issues

All electrical installation and/or repair work is to be carried out by

The heating system is supplied with three safety valves:

The safety valves are set to open at following pressures:

Especially, please be aware of the following liquids:

Transport Pallets To be returned to manufacturer or

4.1 Main data

Heating system CONRAD™ 600 XL

Hot water tank: mm 4000 1430 1610

Heating system CONRAD™ 600 XL

Heating system CONRAD™ 600 XL

Circulated chilled water

Circulated chilled water heating zone 10

All pumps are of the manufacture KSB.

Hot-water tank: 4300 litres

Cold-water tank: 10000 litres

Expansion tank: 1500 litres

4.1.1 Cold water tank unit, sketch

4.1.2 Hot water tank unit, sketch

4.1.3 Hot water tank, sketch

4.1.4 Cold water tank, sketch

4.1.5 Regulating units, sketch

Up to a year: Dry, frost-free and dust-free rooms protected from sunlight.

Please see recommended arrangement on the installation drawings:

CONRAD line : 1172575, 1172406, 1172992, 1172644 & 1173447

5.2 Erection of pipe system

5.3 Handling of components

5.4 Pressure test of the heating system

A pressure test report with the following contents must be made:

Date of pressure test

5.5 Insulation of pipes and tanks

5.6 Charging water into the system

Causes of LOW-LEVEL ALARM could for instance be:

- Leak in heat exchanger for water heating.

5.6.1 Water quality

Analysis of a suitable water quality:

Conductivity: below 20 μS/cm

6.1 Operational modes

If the temperature of the circulating water in any of the heating zones 1 to 4 is

EMERGENCY COOLING can be activated when vacuum failure appears.

6.2 Hot water tank - Temperature control

During automatic operation the pump G2202 will always be running.

The valve is controlled by a pneumatically operated actuator with positioner operating

HIGH TEMPERATURE ALARM: 145C

6.3 Cold water tank - Temperature control

On the secondary side of the heat exchanger cooling water is circulated.

When EMERGENCY COOLING of the heating plates is performed the temperature in

The set points can be selected from the display.

6.4 Emergency cooling

In EMERGENCY COOLING mode the valves will take position L.

Without air pressure the valves will take position L.

6.5 Expansion vessel

The set points can be changed from the display.

6.6 Arrangement for heating regulation units

Each unit in zones 1 to 11 comprises: